MCI-2020_Long_Term

Corrosion_Test
(1994 November ~ 1999 April)

Final Test Result conducted and reported by:

GENERALBUILDING RESEARCHCORPORATION of JAPAN

CORTEC CORPORATION
4 119 White Bear Parkway
. St. Paul. M N 5 5 110 USA
Phone 651-429-1
100
Fax 651-429-1
122
info@cortecvci.com

E-mail:

1. Introduction
This is to reportthe test resultconductedand performedby GBRC, duringthe period,startingfrom 1994 November
to 1999 April, requestedby CORTEC CORPORATION(4119White Bear Parkway,St. Paul, MN 55110 USA), on
migratingcorrosioninhibitor MCI-2020 manufacturedby Cortec Corporationin the aspect of its corrosion
protectionproperty.
Accordingto the resultobtainedat the time of 8 months and also 3years and 7months,after the applyingof MCI2020 to coat on specimens,the differencesof corrosiondegreesbetweenthe one repairedwith MCI-2020and unrepairedare clearlyshowed up with and confirmedthat MCI-2020is workingto protectembodiedrebar. This report
says and leads us to the conclusion of the effectivenessof corrosionprotectionfor rebarsembodiedinsideof concrete
specimens,whichare repaired,appliedand coatedwithMCI-2020,migratinginto concretespecimens.
2. TestingMethod
The concretespecimensare preparedhaving 3 kg/m3 of Cl2 from the beginningand given an initialcuring for 60
days and after observationthey had corrosion, MCI-2020was appliedand coated on the one and left un-treatedfor
the othersto make comparisonbetweenthem.
After the initialsaid 6o days of curing,all the specimensare put into the high temperaturechamberand given further
corrosionaccelerationby repetitionof dry and high humidity.
The measur
ementsof corrosion weightloss were done at 303 days, 488 days, 1,371
days and 1,51
1 days onrebars
in the specimens.With these measurements and result, the effectivenessof corrosion protectionrepairingmethod
using MCI-2020was confirmed.
3. Conditionof specimens
1) Materialof Specimens
As shown below Draw _1, the specimensis in rectangularparallelepipedconcreteand have embodiedrebars(polished
steel bar) at cover thickness2 cm and3 cm from the tops.
Duringthe courseof this test,the corrosiondegreeof theserebarsare determinedthe quantity.
Test rebar : 13mm polishedsteel bar (JIS G3123 SGD-290-D)
13mm,

Cold FinishedCarbonand AlloySteelbars (JIS G3123)

supplementrebar : D10mmdeformed steelbar (JIS G3112 SD 345)
D10mm, SteelBars for ConcreteReinforcement
(JIS G3112)
25

100 10 100 25
13 Polishedroundsteel bar
30

20

30

30

Mini-sensor

150

Mortar
3 Roundbar
D10Deformedbar
260

30
150
Unit : mm

2) ConcreteMix
The materialsused to make specimensare shown belowin Chart-1. The specimenswere made on 1994 Nov 8th.

cement : Ordinaryportlandcement (JIS R5210)

bigger sizaggregate
: Crushedstoneaggregate(Maximumsize:20mm)
smaller aggregate
: mixturesands :sea sands 50% crushedsands 50%

Chart-1 Concretemix proportion

Unit weight(kg/m3)
W/C
S/A
water
Cement
(%)
(%)
W
C

Aggregate: A
FineS

Coarse G

Chemical
Admixture(C %)

65

831

958

0.73

47.2

Ordinarycement

190

292
: W/C=65%

Chlorideion content
Chemicaladmixture
Slump
Air content
Compressivestrength

: 3 kg/m3
: Air entrainingwaterreducingagent
: 19.5cm
: 3.8%
: 29.3N/mm2 at 28days

3) Numberof specimensprepared
Specimenspreparedaccordingto the above1) and 2) specificationis 17 and used for the test..
for observationof corrosionon rebar curedinitiallyfor 60 days / control: 14 piece
specimensuntreated
- 7pieces (three kinds of aging)
(totallyuntreatedfor all the testingperiod)
specimenstreatedafter60 days - 4 pieces(threekinds of aging)
(treatedafter60 days)
specimenstreatedaftercrackappeared - 5 pieces
(treatedat 1,371 days_
4) CuringCondition

The followingcuringwas given to the specimenunderthe conditionof ;

1) To remoldnext day of molding,all the specimenwere startedbeing curedfor 60 days under the temperature
at 20 C , humidity100%RH,as the initialcuring.
2) Then cured in the room for 14 days at 20 C, humidity65%RH. Duringthis period,at 7th day, repairingwith a
coat of MCI-2020 was givento specimens.
3)
In order to acceleratea corrosion,curedwith followingdrying/wettingalternationby a week.
Dryingcondition: at 50 C , belowhumidity30%RHfor one week.
Wetingcondition: at 40 C, humidity100%Rhf for one week
5) MCI2020coating
Duringthe above mentioned2 period, MCI-2020was coatedwith 333g/m2 with brush all the surfaceof specimens.
The coatingwith brush was conductedin 2-3 times to achievethe standardquantity,which took one hour to coat.
6) Evaluationof corrodedrebar
To evaluatethe degreeof corrosionon rebarsin the specimens,the weightof rebarswere measuredafter specimens
were destructedand rebars were taken off and brushedwith wire to remove corrodedparts ( rust, corrosion)using
CLEAR RUST (UK, rust remover). Then the weightloss of rebars was measuredafter washingby clean water and
drying.
To figure out the timing of destruction/me
asurement, Mini-Sensor were set on the surface of rebars and
embodiedtogetherto know an electrochemical
behavior/ changeof the rebars,thus the timingwere so decided.
4. RESULT
The resultof testsis shown accordingto the differenttest condition.
Chart-2.1
:at the time of 60 days aging,corrosionlevelof Rebarsand untreatedtest pieces
Chart-2.2
:test pieceshavingan initialtreatment
Chart - 2.3
: resultof test piecestreatedwith MCI-2020after some cracksappeared.
Picture-2
:relativecorrosionspeedby each aging period.
Picture-3.1~3.3
:Corrosionlevelof rebars(ageing 60 days, 303 days, 488days)

5. AboutCorrosionprotectionof MCI-2020
1) Untreated rebar is gettingheavy corrosion form the start and constantlyfor the period. At 303
days, some of the
specimenshad cracks(#46). Duringthe test period,the corrosion speed is that
rebars/at3cm depthgot 73~93 m/year, rebars/at 2 cm got32~72 m/year. ( refer to Chart2.1)
2) As for untreatedspecimen,ageing between 1371~1543daysperiod the relativecorrosionspeed
shows that corrosionwas changedappearingdramatically
. (Picture2). In figuringout, rebar at 2cm
depth got negativeone(-152m/year),rebar at 3cm depth got big one (351m/year). It means
that there must be some variancein gettingcracksappearedon specimensdependon its condition(

earliestat 300days or so) which gave some influences on the averagecorrosionspeed betweenthe
periodof 1371~1543 days. It came from one or two specimenthough.Accordinglywe must say the
result of corrosionspeed detected between that period would not be a proper indicationand
referencescame out from this experiment. In additionto say, there are also some variancewith
untreatedspecimenshowingabouttwo times (43~77m/year,1371~1543days , Chart 2.1).
3)
Treatedspecimenwith MCI-2020at 60 days shows about 1/6 of corrosionspeed comparedto
untreatedone at the
day of 428 ( Chart 3), means that MCI-2020succeededto protect rebar
controllingcorrosion speedwell.
A g e i n60~303
g
d a ypse r i o: ud n t r e a tspecimen
ed
72~73m/year
corrosionspeedratio
Ageing60~488 daysperiod: treatedonewithMCI-2020 12~14m/year
=
0.17~0.19(?1/6))

4) The result of detectionof untreatedspecimen after 303 days and treatedone after 488 days is shown in
the Chart 2 from which we could say the corrosionspeed is well controlleduntil 1371 days havingthe ratioof
0.53~0.17 (on rebars stationedat the range of 2cm depth and at 3cm depth) and the corrosionspeed is
decreasedby _~1/6.
1) The comparisondata based on the weight loss and calculationsof corrosionspeed measured/obtainedby
breakingspecimensat 1371 days and 1543 days is shown in Chart 2.1&2.2.
In long term ageingthe varianceof corrosion speed appeareddifferentlycausingby specimenscondition,it could be
concludedthat the corrosionspeed is well controlledand reducedby 1/3~1/5.
_ Ageingat 1371days : untreatedspecimen 66.0*m/year
corrosionspeed/rate
_ Ageingat 1371 days : treatedwithMCI-2020
19.5*m/year
= about 0.30
_ Ageingat 1543 days : untreatedspecimen 69.5*m/year
_ Ageingat 1543 days : treatedwithMCI-202015.0*m/year

corrosionspeed/rate
= about 0.22

(*
averagedones at 2cm and 3cm depth rebars)
6) As for the specimensre-treatedwith MCI-2020at the time when some cracks appeared,they had a big
differencesin gettingcracksneeding/waitingfor 1371 days to have finallyeach one has cracks. Then we had
only 6 months to get the result of corrosionprotectionon them, which was too short to concludeclearly.
As a short result for a reference, the result is shown in Chart 2.3. Remarkablysaid from the result,the
corrosionspeed of untreatedspecimengot about two time quicker with 2cm rebar during the period of
1371~1543 days (43m/year 77m/year),on the other hand, treatedone had no increaseof its speed
even at thedays of 1543 (37m/year).From this result it is concludedthat the treatmentwith MCI-2020
worked very well in controllingeven applyingon the corroded rebar and crackedspecimens. However,we
could not observethe same with 3cm rebar since there was big varianceamong the specimensand could not
catch the corrosiontendencyeven on untreatedspecimens.
Throughthe corrosiontest specifiedthis time, we could concludethat coatingtype of corrosioninhibiterMCI-2020
does controlthe corrosionspeedof rebarsembodiedin the concretehavingCl2 3kg/m3 .

When MCI-2020appliedinitially,the corrosionis well controlledreducingits speed by 1/6 during the period
beforecracksare appeared.

At mediumterm between303 388 days,the corrosioncontrolis reducedby about1/3 1/5.

In case applyingMCI-2020at cracksappeared,it is said that MCI-2020worksvery well on rebar at 2cm depth
but it istoo short to confirmits propertyin other case (cm).
In addition,there is no officialcoherencetellingthe experimentalresultof corrosiontest correspondingto the actual
protectionperiod,but it is so evaluatedand concludedfrom the test that MCI-2020 could work to extendthe life of
rebar reducingits corrosionrate by 6 times longer. In other words,it is consideredthat when MCI-2020is applied
at ratherearlierstage of corrosion,it does work so well afterwardsin controllingcrackscomingby 6 times longer of
period., whichis the remarkablecorrosionprotectionpropertyMCI-2020has.
6) The personsin chargeof actualexperiment

Materialexperimentroom:Dr.. MasaruNagayama
Ooyodoexperimentroom: Mr. KazuyukiShimozawa

Picture -1__Reinforced concrete specimen: sizing

Picture - 2_ Relative corrosion rate by each ageing period
Picture- 3.1_Corrosion of rebar: unfold(ageing 60 days)
Picture- 3.2 Corrosion of rebar : unfold (ageing 303days,untreated specimen #46)
Picture- 3.3 Corrosion of rebar : unfold (ageing 488days,MCI2020 treated specimen #53)